Prazo para Manutenções CH05

EXTRA - FLUGZEUGBAU GmbH
SERVICE MANUAL EXTRA 300

CHAPTER 05
PAGE 1
PAGE DATE: 31. January 1995
Chapter 05
Time Limits/ Maintenance Checks
CHAPTER 05
PAGE 2
Table of Contents
Chapter Title
05-00-00 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
05-10-00 TIME LIMIT COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
05-10-01 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
05-10-02 Overhaul Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
05-10-03 Recommended Replacement Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
05-20-00 SCHEDULED MAINTENANCE CHECKS . . . . . . . . . . . . . . . . . . . . . . . 6
05-20-01 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
05-20-02 25 Hour Inspection - Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
05-20-03 25 Hour Inspection - AircraIt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
05-20-04 Maintenance Checks Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
05-20-05 SigniIicant Items Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
05-50-00 UNSCHEDULED MAINTENANCE CHECKS. . . . . . . . . . 32
05-50-01 Violent Stopping oI the Engine (Propeller Strike) . . . . . . . . . . . . . 32
05-50-02 Hard Landing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
05-50-03 Engine Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
05-50-04 Lightning Strike. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
05-50-05 Flightline Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
CHAPTER 05
PAGE 3
05-00-00 GENERAL
This chapter contains charts Ior time limits, scheduled
maintenance and unscheduled maintenance, and enables
licensed personnel to carry out correct inspections on the
EXTRA 300. The periodic inspections and checks de-
scribed and their recommended time intervals are minimum
requirements Ior maintaining the aircraIt in an airworthy
condition. Further inIormation will be given by the inIor-
mation service (Service Bulletins, Service Letters, etc.).
II operation oI aircraIt requires more Irequent servicing, the
check intervals may be shortened. However the check
intervals must not be exceeded without explicit permission
Irom the regulatory authority. Additional checks as well as
changes must also be agreed by the regulatory authority.
In general this Manual does not give any inIormation about
vendor equipment. Such inIormation can be taken Irom the
vendor equipment maintenance instructions (reIer to Chap-
ter 01). However Ior practicability reason most oI the
applicable vendor equipment inspections are incorporated
in the Iollowing checklists. But it has to be noted that the
latest editions oI inspections given by the vendors remain
decisive. So, beIore beginning an inspection, the inspec-
tions oI vendor equipment presented here must be com-
pared with the originals reIerenced under the respective
headlines oI the checklists, and, in case oI doubt (e.g. iI
originals have changed beIore changes could be transIerred
to this Manual by the Revision Service), contact EXTRA-
FLUGZEUGBAU GmbH Ior advice. The maintenance
instructions reIerenced in the checklists are also valid iI
Iurther inspection oI vendor equipment is necessary.
N O T E For working with checklists refer to Chapter 02-20-03.
D A N G E R Do not rotate the propeller nor allow any person to stay
in the propeller operating area when performing an in-
spection or check with the master switch "ON" and the
battery connected. The engine may be started un-
intentionally and may cause serious injuries or death.
PAGE DATE: 1. June 1996
CHAPTER 05
PAGE 4
05-10-00 TIME LIMIT COMPONENTS
05-10-01 General
All components not listed herein should be inspected as
detailed in Chapter 05-20 ,Maintenance Checks' and re-
paired, overhauled as required. It is recommended that
overhaul or replacement oI components should be accom-
plished not later than the speciIied period oI operation Ior
that component or in accordance with the manuIactures
service data or airworthiness directives.
05-10-02 Overhaul Schedule
Items shown here must be overhauled at the times indi-
cated.
1JA LAHD=K
Engine
(Textron Lycoming)
*
Engine accessories
together with
engine
Magneto
(Slick)
*
Double magnetos
(Bendix)
*
Propeller
(MT-Propeller)
*
Governer
(Woodward)
*
All other components on Condition
* refer to latest issue of
Manufacturers Service Bulletin
CHAPTER 05
PAGE 5
TIME LIMIT COMPONENTS
05-10-03 Recommended Replacement Times
It is recommended to replace the items shown in the
Iollowing schedule at the times indicated. The times may be
modiIicated by the respective national authorities.
** on the recommendation
of the manufacturer
1JA 4AF=?A
Battery
(Sonnenschein)
2 years **
Batteries of the ELT
(Pointer)
2 years **
Wheels
(Cleveland, Parker)
on Condition
Tires on Condition
Fuel, oil & brake hoses
(Aeroquip)
after first 7 years,
then 5 years
Seat belts
(Hooker)
6 years **
Brake and Brake Assembly
(Cleveland, Parker)
on Condition
Rudder control cable on Condition
Fairleads on Condition
Shock mounts (Lord
Kinematics, Barry Controls)
on Condition
Bolts and Nuts on Condition ***
*** if not stated otherwise
CHAPTER 05
PAGE 6
05-20-00 SCHEDULED MAINTENANCE CHECKS
05-20-01 General
Scheduled maintenance checks or tasks must be carried out
at 25, 50, 100, 200, 300, 400, 500 and 1000 hour intervals.
In addition an annual inspection equal to the 100 hour
inspection has to be perIormed.
The Iollowing pages show a drain hole chart (Figure 1) and
lubrication charts (Figures 2 - 4) which can be used in
connection with the checklists.
05-20-02 25 Hour Inspection - Engine
A 25 hour inspection is necessary Ior the engine, because
the engine is not equipped with an external oil Iilter.
ThereIore the engine oil has to be changed and the oil screen
cleaned aIter every 25 hours. ReIer to Figure 2 "Lubrication
Chart 25 hours".
05-20-03 25 Hour Inspection - Aircraft
AIter the Iirst 25 hours, a check equal to the 100-hour
maintenance check has to be perIormed. ReIer to Chapter
05-20-04.
CHAPTER 05
PAGE 7
rain and Jent Holes
Figure 1
SCHEDULED MAINTENANCE CHECKS
1. Root Rib Aileron
2. Root Elevator
3. Root Hori:ontal Stabili:er
4. 1rim1ab (3 Holes)
5. Stall Warn 1ransducer
6. Lower Root Rudder Fin
7. Lower Root Rudder Horn
8. Wheel Fairing
9. Nose Ribs Aileron (Hinge Gaps)
CHAPTER 05
PAGE 8
Lubrication Chart 25 hours
Figure 2
CHAPTER 05
PAGE 9
Figure 3
CHAPTER 05
PAGE 10
Figure 4
CHAPTER 05
PAGE 11
05-20-04 Maintenance Checks Schedule
The maintenance checks described in this Chapter include
all the scheduled checks which must be perIormed. Use the
Iollowing schedule and the lubrication charts (Figures 2-4).
Operational Checks
O O 1 Start engine (in accordance with the Pilot`s Operating Handbook)
O O 2 Check the Iuel quantity indication.
O O 3 Check oil pressure and temperature.
O O 4 Check generator output.
O O 5 Check magneto RPM-drop at 1800 RPM. (Allowed drop is
175 RPM and no greater diII. between L R Irom 50 RPM)
O O 6 Check ignition OFF Iunction at 1000 RPM Ior a short
moment.
O O 7 Check response oI the engine by power setting changes.
O O 8 Check the Propeller response at 1800 RPM when changing
pitch.
O O 9 Check idle speed is between 650 and 750 RPM.
O O 10 Check the Iuel Ilow and maniIold pressure indicator.
O O 11 Check the EGT and CHT indicator.
O O 12 Check mixer Iunction per CHT/EGT indication.
O O 13 Check idle mixture.
O O 14 Check the Iunction oI the Iuel selector valve.
O O 15 Check the radio and the other electronic equipment.
O O 16 Shut down engine using mixture lever. Check the alternator
warning light or ammeter.
Inspector:
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Inspections
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CHAPTER 05
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Inspector:
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Inspections
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Maintenance Checks Schedule
O O 17 Check the optional electronic g-meter Ior the maximum g-
loading. II extreme value exceeds +10 G, contact EXTRA-
Flugzeugbau GmbH. Correct date and time oI the g-meter
(reIer to DSA-12 Manual).
O O 18 Ignition OFF, main switch OFF, remove ignition key.
O O 19 Check iI ignition key is removable in OFF-position only, and
iI key Iunctions in accordance with the requirements oI the
Teledyne Continental Service Bulletin No. 636.
Propeller
(reIer to latest edition oI MT-Propeller Operation and Instal-
lation Manual E-124 and Service Bulletins)
Ground magneto primary circuit before
working on propeller
O 1 Remove spinner and check Ior cracks.
O O 2 Check blade shake, max. 3 mm or 1/8 inch.
O O 3 Check blade angle play, max. 2.
O 4 Inspect outside condition oI the hub and parts Ior cracks,
corrosion, deterioration.
O 5 Inspect check nut Ior high pitch stop Ior tightness.
O O 6 Check all saIety means to be intact.
O O 7 Check Ilange bolts or stopnuts Ior tightness.
O 8 Check Iront and rear spinnerplate Ior cracks and Iixing.
O O 9 Inspect bladeroot and hub Ior oil- and grease leaks.
O 10 Check position and condition oI counterweights.
O O 11 Check blades Ior cracks in the Iibreglass-cover and blade
erosion sheet. No cracks allowed. ReIer to MT-Propeller SB
No. 8
O
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12 Overhaul propeller or perIorm a tear-down inspection.
D A N G E R
1 refer to M1-Propeller Service Bulletin No. 1
CHAPTER 05
PAGE 13
Inspector:
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Inspections
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Engine compartment
(ReIer to latest edition oI Textron Lycoming Operators
Manual and SB's, oI Christen Product Manual 801 Series and
SB's, oI Slick Magneto Maintenance and Overhaul Manual
and SB's and oI TCM/Bendix Service Support Manual,
included in Form X40000 Master Service Manual and SB's)
Ground magneto primary circuit before
working on engine
O O 1 Remove engine cowling.
O O 2 Inspect cowling and air inlet screen Ior damage, cracks,
distortion, overheated areas and loose or missing blindnuts
and secure attachment oI oil level access plate.
O O 3 AIter this inspection clean cowling.
O O 4 Check Iire protection according to EXTRA Service Bulletin
300-6-94. II necessary repaint the Iire protection paint
("WIEDOFLUGAT" BrandschutzIarbe N 56582 / T508).
O
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O O 5 Drain oil sump in accordance with Chapter 12-10-04 'En-
gine Oil Replenishing
O
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O O 6 Clean and inspect oil screen Iilter
O
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O O 7 Clean suction oil strainer at oil change (check strainer Ior
Ioreign particles).
O
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O O 8 Clean pressure oil strainer (check Ior Ioreign particles)
O
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O O 8a Change Iull Ilow (cartridge type, AEIO-540-L1B5/D en-
gine) oil Iilter element (check element Ior Ioreign particles).
O 9 Inspect oil temperature sensor unit Ior leaks and security.
O O 10 Inspect Ilexible oil lines, oil return lines and Iittings Ior leaks,
security, chaIing, dents, and cracks (reI: FAA AC 43.13-1A).
Replace Ilexible oil lines at engine TBO per Lyc. SB 240.
Check Iire protection according to EXTRA SB 300-6-94.
O 11 Clean and inspect oil radiators and attachment.
O
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12 Remove and Ilush oil radiators.
D A N G E R
1 at 10 and 25 hours and then each 25 hours
2 at 10 and 25 hours
3 each 500 hours
PAGE DATE: 15. December 1999
CHAPTER 05
PAGE 14
Inspector:
Mechanic:
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Inspections
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O O Inspect Christen Inverted Oil System Ior general condition,
leaks, secure mounting and tight connections.
O
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13 Clean and Ilush the Inverted Oil System with a suitable
petroleum solvent, such as varsol according to Lycoming
Operator`s Manual.
O
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O O 14 Service engine with recommended lubricating oil in accord-
ance with Chapter 12-10-04.
O O 15 Inspect condition oI spark plugs (Clean and adjust gap as
required, adjust per Lycoming Service Instruction 1042). II
Iouling oI spark plugs has been apparent, rotate buttom plugs
to upper plugs and vice versa.
O O 16 Inspect spark plug cable leads and ceramics Ior corrosion and
deposits.
O O 17 PerIorm a hot engine diIIerential compression check in
accordance with FAA AC 43.13-1A.
O 18 Inspect cylinders Ior cracked or broken Iins.
O O 19 Check cylinders Ior evidence oI excessive heat which is
indicated by discoloration.
O 20 Check Iuel injector nozzles Ior loseness. Tighten to 60 inch
pounds torque. Check Iuel lines Ior Iuel stains which are
indicative Ior Iuel leaks.
O O 21 Inspect rocker box covers Ior evidence oI oil leaks. II Iound,
replace gasket; torque cover screws 50 Inch-pounds.
O
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22 Remove rocker box covers and check Ior Ireedom oI valve
rockers when valves are closed. Look Ior evidence oI abnor-
mal wear or broken parts in the area oI valve tips, valve
keeper, springs and spring seats.
O 23 Inspect ignition harness Ior general condition, Iree Irom
Iraying or chaIing and insulators Ior high tension leakage and
continuity.
1 each 300 hours
2 each 25 hours
3 each 400 hours
CHAPTER 05
PAGE 15
1CM/Bendix magnetos
O 24 Check magneto-to-engine timing.
O 25 Remove all ignition harness spark plug terminals Irom spark
plugs, clean and inspect Iollowing the respective sections oI
the applicable Support Manual.
O 26 Inspect magnetos with riveted impulse coupling Ior wear as
speciIied in the latest revision oI TCM/Bendix SB 599D.
O
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27 Inspect magnetos equipped with snap-ring impulse coupling
Ior wear as outlined in the PERIODIC MAINTENANCE
Section oI the applicable Support Manual, Paragraph 6.2.2.
O
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28 Inspect magnetos as outlined in the PERIODIC MAINTE-
NANCE Section oI the applicable Support Manual, Para-
graph 6.2.3. Clean and inspect all ignition harness outlet
plates, covers or cap assemblies and grommets Iollowing the
respective sections oI the Manual mentioned above.
O
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29 Overhaul or replace magnetos acc. to TCM/Bendix SB 643.
Slick magnetos
O 24 Adjust magneto to engine timing, reIer to Slick Magneto
Maintenance and Overhaul Manual
O 25 Inspect wiring connections, vent holes and P-lead
attachment, reIer to Slick Magneto Maintenance and Over-
haul Manual.
O
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26 Clean magnetos.
O
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27 Inspect ball bearing assembly, impulse coupling, coil, con-
tact points, condenser and carbon brush.
O
3
28 Replace ball bearings.
O
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29 Lubricate magnetos.
O
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30 Overhaul or replace magnetos.
Inspector:
Mechanic:
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Inspections
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1 each 500 hours
2 at engine overhaul and at the expiration of 4 years
3 each 1000 hours
4 together with engine
CHAPTER 05
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O 31 Check Iuel injector Ior general condition, clean Iuel inlet
screen.
O O 32 Inspect intake seals and O-rings Ior leaks and clamps Ior
tightness.
O O 33 Inspect Ilexible Iuel lines, Iuel injection lines and Iittings Ior
leaks, security, chaIing, dents, and cracks (reIer to Lycoming
SB 342 each 100h; replace or overhaul as required or at
engine overhaul). Check Iire protection according to EXTRA
SB 300-6-94.
O O 34 Check Iuel system Ior leaks.
O
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O O 35 Remove, clean and inspect gascolator screen and Iuel Iilter
bowl.
O O 36 Inspect throttle, mixture, and propeller governor controls Ior
security, travel, and operating conditions.
O O 37 Inspect exhaust stacks, connections and gaskets (replace
gaskets as required).
O O 38 Inspect exhaust slipjoints Ior general condition.
O O 39 Inspect exhaust system attachment.
O 40 Inspect crankcase Ior cracks, leaks, and security oI seam
bolts.
O O 41 Check engine mounted accessories such as pumps, tempera-
ture and pressure sensing units Ior leaks, secure mounting
and tight connections.
O O 42 Inspect engine mount Ior cracks and loose mountings.
O O 43 Inspect engine baIIles Iree Irom cracks and Iraying.
O 44 Inspect all wiring connected to the engine or accessories
O O 45 Inspect engine shock mounts Ior deterioration (replace as
required).
O 46 Inspect Iirewall seals (see EXTRA SB 300-6-94).
O 47 Inspect alternator, cable connections and accessories.
1 clean at least every 90 days
CHAPTER 05
PAGE 17
Inspector:
Mechanic:
Date:
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Inspections
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O 48 Inspect condition and tension oI alternator drive belt
O 49 Inspect security oI alternator mounting
O 50 Inspect starter and starter drive
O O 51 Check brake Iluid level (Iill as required).
O O 52 Clean engine iI necessary.
O O 53 Lubricate all controls per lubrication chart.
O
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54 Overhaul or replace propeller governor as required.
O
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55 Complete overhaul oI engine or replace with Iactory rebuilt
O O 56 Reinstall engine cowling.
Fuselage
O O 1 Remove tail Iairing, tail side skins, tank covering sheet, turtle
deck and landing gear cuIIs per Chapter 51.
O 2 Remove bottom covering window and sheets including ex-
haust area covering sheet per Chapter 51.
O O 3 Inspect tank covering sheet, turtle deck, bottom covering
window and sheets including exhaust area covering sheet,
tail Iairing, tail side skins and landing gear cuIIs Ior general
condition, dents, cracks and loose screws and rivets.
O O 4 Check installed parts Ior general condition and security oI
attachment.
O O 5 Inspect Iuselage Ior Ioreign matters.
O 6 Inspect steel tube construction Ior general condition, corro-
sion and cracks, above all in areas oI load stress (e.g. wing,
stabilizer, engine and seat attachments).
O O 7 Visually inspect steel tube construction in the area oI hori-
zontal stabilizer attach brackets Ior cracks. In case oI doubt
remove horizontal stabilizer and use a dye check penetrant.
In case oI cracks are Iound contact EXTRA-FLUGZEUGBAU
GmbH Ior repair advise.
O O 8 Inspect Iabric cover Ior general condition.
1 refer to Woodward Service Bulletin No. 33580
2 refer to Lycoming Service Instruction No. 1009
CHAPTER 05
PAGE 18
Inspector:
Mechanic:
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Inspections
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O 9 Inspect wooden longerons Ior damage.
O 10 Clean and lubricate canopy hinge and latching mechanism.
O O 11 Inspect seats and seat belts Ior security, attachment, proper
operation, and condition. Control the time limit oI the seat
belts. ReIer to Chapter 05-10-02 "Overhaul Schedule".
O 12 Inspect breather line Ior obstructions and security.
O 13 Inspect main and auxiliary wing spar connector Ior general
condition.
Fuel system
O O 1 Inspect the Iuel lines Ior leaks, security, chaIing, dents and
cracks. Replace Iuel lines as required.
O O 2 Inspect Iuel selector valve Ior operation and proper pointer
indication
O O 3 Drain Iuel system
O O 4 Check acro- and center tank attachment
O O 5 Check acro-, center- and both wingtanks Ior leaks
O O 6 Check boost pump
O O 7 Check Iuel Iiller caps Ior security and proper operation
O O 8 Check proper seat and condition oI sealing lip (Irom S.No 59)
Flight controls
O O 1 Remove wing access panels.
O O 2 Inspect control surIaces Ior security oI attachment, Iree
movement, dents, delaminations and cracks.
O O 3 Inspect elevator trim system Ior proper operation and rigging.
O O 4 Inspect hinges Ior condition, cracks and security; hinge bolts,
hinge bearings, selIlocking nuts.
O O 5 Check Iree play in control system: torque tube, control
surIaces, control sticks, rod end bearing, deIlector limiter.
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O O 6 Lubricate rear torque tube bearing.
1 each 25 hours
CHAPTER 05
PAGE 19
Inspector:
Mechanic:
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Inspections
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O O 7 Lubricate aileron rodend bearings, trim Ilap hinges and trim
lever bolt.
O 8 Lubricate adjustment tube oI electrical pedal adjustment.
O O 9 Check rudder cable system including sleeves, Iairleads,
pulleys and cable retracting springs per FAA-AC 43.13-1A.
O 10 Check Ior minimum 3.5 mm (1/8") clearance oI rudder pedal
versus saIety stop when Iully deIlected Ior rudder cables
having 50 h Ilight time minimum. On newly installed rudder
cables the minimum spacing is 6 mm (1/4"). ReIer to Figure 5.
This check is to be perIormed with zero loading on the rudder
pedals.
O 11 Rough check oI saIety stop clearance. With a Iorce oI approx.
90 kg (200 lbs) acting on the Iully deIlected rudder pedal the
saIety stop shall not be reached. II the stop is reached the
control system indicates a too high Ilexibility which needs to
be traced. In this case contact EXTRA Ior advice.
O O 12 Inspect all Ilight control ventilation holes Ior obstruction.
O 13 Inspect elevator balance weight Ior looseness and condition.
O 14 Inspect push rods.
Landing gear
O O 1 Check landing gear Ior general condition.
O O 2 Check landing gear spring Ior dents and cracks.
O O 3 Inspect landing gear spring mounting clamps and bolts Ior
security.
O 4 Lubricate landing gear center bolt and landing gear bearings.
O 5 Check wheel rake (10 + 0.5) and toe-in (1.5 + 0.5) per
Chapter 32.
Fairings:
O O 1 Disassemble Iairings.
O O 2 Check Iairings Ior dents and cracks.
O O 3 Check Iairing ventilation hole Ior obstruction.
CHAPTER 05
PAGE 20
Wheels
(reIer to on-aircraIt inspections presented in the latest edition
oI Cleveland Wheels & Brakes Maintenance Manual and
Service Bulletins Ior wheel, tire and break inspections)
O O 1 Visually inspect the wheels Ior corrosion, cracks, or other
visible damage.
O O 2 Check wheel nuts to be sure they are properly installed and
have not worked loose. Bolt threads should be Ilush to 1-1/2
threads extending beyond the nut. Nuts should be on the side
oI wheel opposite the brake disc (outboard side oI wheel).
O O 3 Inspect the brake disc Ior rust, excessive grooves, large
cracks, coning or other visible damage. Check iI disc thick-
ness is more than 0.325in/8.255mm. Coning oI disc in excess
oI 0.015 in /0.381 mm is cause Ior replacement (see Fig. 6).
O 4 Remove wheels and wheel bearings. Inspect wheel bearing
grease Ior contamination and solidiIication.
O 5 Inspect snap rings and grease seals Ior distortion or wear.
Replace grease seal Ielts iI they are hard or contaminated.
Lightly saturate grease seals should be replaced iI cracked,
dried out, or distorted.
O 6 Inspect wheel bearings Ior excessive wear or damage. Re-
place on condition.
O 7 Repack bearings with AEROSHELL 22C (per MIL-G-81322),
or equivalent. Reinstall wheels and saIety.
O O 8 Check wheel bearing clearance and wheels Ior Iree rotation.
1ires
O O 1 Visually inspect tires Ior cuts, Ilat spots, and tread or sidewall
damage. II changing oI tires is necessary Iollow the instruc-
tions, including oII-aircraIt inspection oI wheels, presented
in the Cleveland Wheels & Brakes Component Maintenance
Manual.
O O 2 Check inIlation pressure (3.4 bar / 49.3 psi). Proper inIlation
will provide maximum tire and wheel liIe.
Inspector:
Mechanic:
Date:
Serial No.:
Inspections
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Brake system
O O 1 Inspect brake assemblies Ior general condition.
O O 2 Inspect master cylinders Ior leaks.
O 3 Inspect brake system plumbing Ior leaks and hoses Ior bulges
and deterioration.
O 4 Lubricate brake guide pins using Silicone-base lubricant.
O O 5 Visually inspect the brakes Ior corrosion, cracks, or other
visible damage. Check inlet Iitting bosses and anchor bolt
lugs Ior cracks. Check inlet Ilares on aircraIt side oI rigid
hydraulic tubing Ior Iatigue cracks.
O O 6 Check back plate attachment bolts to insure they are properly
torqued and have not worked loose. Gaps between the back
plate and cylinder would be evidence oI this.
O O 7 Check Iit oI brake cylinder anchor bolts in torque plate
bushings Ior sloppiness. This can be accomplished by grasp-
ing the cylinder and moving it; slight movement is normal.
Excessive movement is cause Ior removal and detailed
inspection.
O O 8 Linings should be visually checked Ior extreme chipping on
the edges. Lining worn to a minimum thickness oI 0.100 inch
(2.54 mm) must be replaced.
O O 9 Visually check torque plate Ior corrosion, cracks, loose
anchor bolt bushings, or other visible damage. Anchor bolt
bushings must be Ilat against torque plate surIace.
O O 10 Check Ior any brake Iluid leaks.
O O 11 Check brake Iluid level.
1ail-wheel landing gear
O O 1 Check tail-wheel landing gear Ior general condition.
O O 2 Check tail-wheel landing gear spring Ior dents, cracks, and
delaminations.
O O 3 Check tail-wheel rubber tire condition.
Inspector:
Mechanic:
Date:
Serial No.:
Inspections
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CHAPTER 05
PAGE 22
O O 4 Inspect tail-wheel spring and swivel arm mounting bolts Ior
security.
a) Standard: Full-swivel tailwheel
O O 1 Check swivel arm Ior dents and cracks.
O O 2 Check tail wheel Ior Iree rotation and swivel Ieature.
O 3 Check swivel arm and wheel bearing clearance, service.
b) Optional: Steerable tailwheel
O O 1 Check Ior general condition and Iunction. Pay attention to
the Iree movement oI the rudder.
O O 2 Check the connector springs Ior light precompression.
O O 3 Check the wheelIork Ior Iree rotation and steering Iunction,
damage, dents, cracks and corrosion.
O O 4 Inspect wheelIork Ior damage, dents, cracks and corrosion.
O O 5 Inspect the axle bolt and nut Ior Iretting, wear, damage, and
stretch.
O O 6 Lubricate tail wheel steering.
Wing
O O 1 Check wing Ior dents, cracks, and delaminations.
O 2 Inspect wing spar main bolts Ior looseness and security.
O 3 Check the saIety wire and the saIety screw oI the wing main
spar bolt.
O 4 Inspect wing spar main sleeves Ior looseness and bearing
load.
O 5 Inspect wing auxiliary spar attachment.
O 6 Inspect wing ventilation holes Ior obstruction.
O O 7 Check inside wing structure in the area oI access panels.
Inspector:
Mechanic:
Date:
Serial No.:
Inspections
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CHAPTER 05
PAGE 23
Inspector:
Mechanic:
Date:
Serial No.:
Inspections
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Stabilizer
O O 1 Check stabilizer Ior dents, cracks; stone nicks and
delaminations.
O O 2 Inspect stabilizer spars main bolts Ior looseness and security.
O O 3 Inspect stabilizer auxiliary spars attachment.
O 4 Inspect stabilizer ventilation holes Ior obstruction.
Instruments
O 1 Inspect panel mounting Ior security and saIety.
O 2 Check operation, mounting, and wiring oI switches Ior
condition and saIety.
O 3 Check automatic circuit breaker mounting and wiring Ior
condition and saIety.
O 4 Inspect stall warner system Ior condition and security oI
installation, perIorm operational check.
O O 5 Check wingtip position/strobe lights Ior security and opera-
tion.
O O 6 Inspect compass and compass deviation card Ior proper
indication and compensation.
O
1
7 Magnetic compass compensation.
O 8 Check pitot /static air pressure lines Ior condition and leaks,
perIorm operational check.
Electrical system
O O 1 Check engine bonding
O O 2 Check tank bonding (wing- and center tank)
O 3 Check system wiring Iree Irom Iraying or cracks
O 4 Inspect battery and attachment
O O 5 Charge battery
1 Annual, each twelve calendar month
CHAPTER 05
PAGE 24
05-20-05 Significant Items Inspection
Every 1000 flight hours the "SigniIicant Items Inspection"
must be perIormed in addition to the 100-hour inspection.
Wing
Leading edge
O 1 Detailed visual inspection on the surIace Ior erosion, scratches, stone
nicks and impact damages.
O 2 Detailed visual inspection on the bonding top/bottom Ior dents,
cracks and delaminations.
O 3 Inspect grounding rivets visually.
Main spar section
O 4 Check bonding skin/spar Ior delaminations by coin tapping (ReIer to
Chapter 20-10-05).
O 5 Detailed visual inspection on the sparweb Ior dents, cracks and
delaminations by visual inspection through wing access holes using
a boroscope.
Auxiliary spar section
O 6 Check bonding skin/spar Ior delamination by coin tapping .
O 7 Detailed visual inspection on the aux. spar web Ior dents, cracks and
delaminations. Pay particular attention to the cutout Ior aileron
cantilever.
O 8 Inspect attachment Iitting Ior damage, corrosion and link bolts
security.
Spar carry-through
O 9 Remove spar cap paint by a solvent. PerIorm visual inspection Ior
dents and cracks. Check Ior delaminations by coin tapping. Restore
Iinish in accordance with Chapter 51-70-05.
O 10 Remove spar web paint by a solvent. PerIorm visual inspection Ior
Inspector:
Mechanic:
Inspections EXTRA 300
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PAGE 25
O 11 Check main bolt sleeves Ior secure bonding to the spar.
Wing trailing edge
O 12 Check bonding top/bottom Ior cracks and delaminations by coin
tapping (ReIer to Chapter 20-10-05).
Root and 1ip
O 13 Check root rib Ior cracks, delaminations and secure bonding to skin
and spars by coin tapping (ReIer to Chapter 20-10-05).
O 14 Inspect tip rib visually Ior general condition.
O 15 Check metall Iittings (power supply support) Ior secure bonding to
the carbon laminate
Aileron
O 1 Check root and tip rib bonding to the skin laminate by coin tapping.
O 2 Check bonding skin/spar Ior delaminations by coin tapping.
O 3 Checkbonding top/bottom Ior cracks and delaminations by coin
tapping (ReIer to Chapter 20-10-05).
O 4 Check hinge points (mounting brackets) and actuator Ior damages and
cracks. Ensure proper attachment.
O 5 Inspect spades visually Ior general condition. Check spade support
Ior corrosion, cracks and deIormations. Ensure proper attachment to
aileron.
O 6 Inspect ventilation holes Ior obstruction.
Surface general
O 1 Check painting visually Ior general condition (blisters etc.).
O 2 Check laminate Ior erosion, scratches and nicks.
Control system
O 1 Inspect bell cranks Ior damage, corrosion, security oI mounting and
link bolts through wing access holes.
O 2 Inspect control rods Ior corrosion.
O 3 Check Rod end bearing Ior Iree movement and cleanliness.
Inspector:
Mechanic:
Inspections
Date:
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SigniIicant Items Inspection
CHAPTER 05
PAGE 26
Vertical Stabilizer
Leading edge
O 1 Check surIace Ior erosion, scratches, stone nicks and impact dam-
ages.
O 2 Check bonding leIt/right Ior dents, cracks and delamination.
Front spar section
O 3 Check bonding skin/spar Ior delamination by coin tapping (ReIer to
Chapter 20-10-05).
O 4 Detailed visual sheet metal attachment Iitting Ior damage, corrosion
and link bolts security.
Rear spar section
O 5 Check bonding skin/spar Ior delamination by coin tapping .
O 6 Detailed visual rear spar web Ior dents, cracks and delamination. Pay
particular attention to the cut out Ior rudder cantilever.
O 7 Check steel sleeve Ior secure bonding to the spar.
O 8 Replace attachment bolts and stop nuts. Check Ior proper torque in
accordance with Chapter 20-10-02.
Root and 1ip
O 9 Check root rib Ior cracks, delamination and secure bonding to skin
and spars by coin tapping.
Rudder
O 1 Check tip rib bonding to the skin laminate by coin tapping.
O 2 Check bonding skin/spar Ior delamination by coin tapping.
O 3 Check bonding trailing edge Ior cracks and delaminations by coin
tapping.
O 4 Detailed visual oI mounting brackets Ior damages and cracks. Ensure
proper attachment. Replace bolts and stop nuts Ior new ones in any
case. Check Ior proper torque in accordance with Chapter 20-10-02.
O 5 Check actuator lever Ior damage, cracks and proper attachment.
O 6 Inspect ventilation holes visually Ior obstruction. ReIer to Chapter
05-20-01, Figure 2 "Drain and Vent Holes".
Inspector:
Mechanic:
Inspections
Date:
Serial No.:
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CHAPTER 05
PAGE 27
O 7 Check painting visually Ior general condition (blisters etc.).
O 8 Check laminate Ior erosion, scratches and stone nicks.
Horizontal Stabilizer
Leading edge
O 1 Check surIace Ior erosion, scratches, stone nicks and impact damage.
O 2 Check bonding top/bottom Ior dents, cracks and delamination.
Front spar section
Rear spar section
Spar carry-through
O 5 Remove spar cap paint by a solvent. PerIorm visual inspection Ior
dents and cracks. Check Ior delamination by coin tapping. Restore
O 6 Remove Spar web paint by a solvent. PerIorm visual inspection Ior
O 7 Replace attachment bolts and stop nuts. Check Ior proper torque in
accordance with Chapter 20-10-02.
O 8 Check steel sleeves Ior secure bonding to the spar.
Root and 1ip
O 9 Check root rib Ior cracks, delamination and secure bonding to skin
and spars by coin tapping.
Elevator
O 1 Check tip rib bonding to the skin laminate by coin tapping.
O 2 Check bonding skin/spar Ior delaminations by coin tapping.
O 3 Check bonding trailing edge Ior cracks and delamination by coin
tapping.
O 4 Detailed visual inspection oI mounting brackets Ior damage, cracks
and proper attachment. Replace bolts and stop nuts. Check Ior proper
torque in accordance with Chapter 20-10-02.
Inspector:
Mechanic:
Inspections
Date:
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CHAPTER 05
PAGE 28
O 5 Check center section Ior delamination by coin tapping.
O 6 Detailed visual oI actuator lever Ior damage, cracks and proper
attachment.
O 7 Detailed visual oI mass balance attachment and mounting boom Ior
deIormation, corrosion and cracks.
O 8 Detailed visual oI trim tab hinges, actuator lever Ior damage, cracks,
excessive wear and proper bonding to the laminate. Detailed visual
Ior delamination.
O 9 Inspect ventilation holes Ior obstruction.
Surface general
O 10 Check painting Ior general condition (blisters etc.).
O 11 Check laminate Ior erosion, scratches, stone nicks and impact dam-
ages.
Fuselage
O 1 Inspect tubular steel Irame visually Ior corrosion, scratches and
damages.
O 2 Check wing main spar attachment Ior damage and corrosion. Inspect
Ior dents and cracks.
O 3 Detailed visual oI the sheet metal oI the wing auxiliary spar attach-
ment Ior damage, corrosion. Inspect the sheet metal supports using a
Iluorescent dye penetrant to insure no cracks are evident.
O 4 Detailed visual oI cockpit Irame visually Ior dents, cracks and
delaminations.
O 5 Inspect main Iuselage cover visually Ior dents, cracks and delamination.
Flight controls
O 1 Detailed visual oI torque tube Ior damages, cracks, Iree-play and stop
adjustments.
O 2 Detailed visual oI bell cranks Ior damage, cracks, corrosion, security
oI mounting and link bolts.
O 3 Inspect control rods Ior loose or popped rivets and general condition.
O 4 Inspect sticks (rear & Iront) Ior Iull travel, proper rigging, Iree-play,
security oI mounting and direction oI control surIace movement with
relation to stick movement.
Inspector:
Mechanic:
Inspections
Date:
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Inspector:
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O 5 Check rod end bearings Ior Iree movement and cleanliness.
O 6 Detailed visual oI trim actuator lever Ior damages and cracks. Ensure
proper attachment and condition oI Iriction.
Main landing gear
O 1 Inspect landing gear spring visually Ior dents, cracks and delaminations,
especally at the axle attachment and the center bushing Ior wear and
looseness.
O 2 Check mounting clamp Ior damage and corrosion. Inspect Ior dents
and cracks.
O 3 Inspect mounting clamp bolts and nuts Ior Iretting, wear, damage,
stretch and proper torque (reIer to Chapter 20-10-03).
O 4 Check brakes discs Ior warping and wear. Inspect wheel brake
cylinder mounting brucket Ior wear.
O 5 Inspect brake lines Ior leakage, dents, cracks, chaIIing, kinks and
security oI anchorage.
O 6 Inspect axle attachment bolts and nuts Ior Iretting, wear, damage, and
stretch.
O 7 Check tires Ior general condition.
Tail-wheel landing gear
O 1 Inspect glass Iibre spring visually Ior dents, cracks and delaminations.
O 2 Inspect mounting bolts and nuts Ior Iretting, wear, damage, stretch
and proper torque.
Standard: Full-swivel tail-wheel
O 1 Check tail-wheel Ior Iree rotation and general condition.
O 2 Inspect swivel arm visually Ior damage, dents, cracks and corrosion.
Check Ior swivel Ieature.
O 3 Inspect axle bolt and nut Ior Iretting, wear, damage, and stretch.
O 4 Check rubber tire Ior general condition.
Optional: Steerable tail-wheel
O 1 Check tail-wheel Ior general condition and Iunction. Pay attention to
the Iree movement oI the rudder.
CHAPTER 05
PAGE 30
O 2 Check connector springs Ior light precompression.
O 3 Inspect wheelIork visually Ior damage, dents, cracks and corrosion.
O 4 Inspect axle bolt and nut Ior Iretting, wear, damage, and stretch.
O 5 Check rubber tire Ior general condition.
Engine compartment
O 1 Check Iirewall Ior dents, cracks and deIormation.Visual inspection oI
PRC-812 seals Ior porosity and general condition.
O 2 Inspect tubular engine mount Ior dents, cracks and corrosion. Check
all bolts Ior security and condition.
O 3 Visual inspection oI rubber mounts (shock mounts) Ior porosity and
general condition.
O 4 Inspect Ilexible hose Ior damage and leakage.
O 5 Visual inspection oI Iire sleeves Ior chaIIing and general condition.
O 6 Check electric wiring Ior proper connection.
O 7 Check grounding straps Ior proper connection.
O 8 Visual inspection oI inverted oil system Ior general condition accord-
ing to CHRISTEN 801instruction. ReIer to CHRISTEN Product
Manual P/N: 70047-001 or to TEXTRON LYCOMING Operator`s
Manual P/N: 60297-21.
O 9 Carry out general engine check as instructed by TEXTRON
LYCOMING Operator`s Manual P/N: 60297-21.
O 10 Visual inspection oI cowling Ior dents,cracks,delamination and smoke
marks.
Hardware
O 1 MagnaIlux or Iluorescent dye-check oI the wing main spar bolts by
authorized personnel is required. (Remove only one bolt at a time).
Inspect Ior security oI the spar bolts and saIety-screws.
O 2 Check harness attachment Iittings Ior cracks, deIormations and
corrosion.
O 3 Check bolts and nuts in critical areas Ior Iretting, wear, damage,
stretch, proper torque and saIety.
O 4 Visual inspection oI center tank Iastening straps Ior cracks, damage
and corrosion.
Inspector:
Mechanic:
Inspections
Date:
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Inspector:
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O 5 Visual inspection oI battery Iastening straps Ior cracks, damage and
corrosion.
O 6 Check the "quick pins" oI the seat adjustment Ior cracks, deIorma-
tions and corrosion. Inspect wear and proper Iunction.
O 7 Visual inspection oI rudder pedal mounting to the attachment Iittings.
Check bolts Ior security.
Surface general
O Visual check oI painting Ior deteriorated paint.
CHAPTER 05
PAGE 32
05-50-00 UNSCHEDULED MAINTENANCE
CHECKS
Unscheduled checks are only perIormed aIter abnormal
events, which could possibly have caused damage to the
aircraIt or impaired the airworthiness.
I M P O R T A N T In case of abnormal events or any exceedance of given
limitations (load factor, never exceed speed, etc.) the
manufacturer has to be contacted to find appropriate
maintenance procedures. Therefore the procedures de-
scribed in the following could be subjected to changes.
05-50-01 Violent Stopping of the Engine (Propeller
Strike)
In a case where the propeller has struck the ground or the
engine has been stopped violently (shock loading), the
complete engine has to be disassembled and checked by an
authorized company. The crankshaIt might be damaged.
The propeller has to be checked and repaired by an author-
ized company according to MT-propeller instruction. Re-
Ier to MT-propeller "Operation- and Installation Manual E-
124".
05-50-02 Hard Landing
AIter an extremely hard landing or other unusual loads on
the landing gear, perIorm a check as described in the
Iollowing, even when there are no obvious signs oI damage:
II there are indications that structural parts are damaged, the
manuIacturer has to be consulted Ior possible and suitable
repair methods.
CHAPTER 05
PAGE 33
Landing gear
O 1 Examine landing gear mounting clamps Ior deIects (e.g. cracks and
deIormed areas)
O 2 Check clamp bolts oI the landing gear Ior cracks, replace when
necessary
O 3 Examine wheel track and check iI measurement correspond to the
value given in Chapter 06-10-01.
O 4 Remove and check the Iairings Ior delamination, deIormations and
cracks
O 5 Check the landing gear spring Ior delamination, deIormations and
cracks, especially in the area oI the axle attachment
O 6 Check Iuselage structure in the area oI landing gear attachment Ior
deIormation and cracks
O 7 Examine wheel base and check iI measurement correspond to the
value given in Chapter 06-10-01.
O 8 Check tires Ior cuts in the side wall
O 9 Check wheel halves and brake discs Ior impacts, cracks and distortion
according to CLEVELAND instruction.
O 10 Check tail wheel Ior deIormation and cracks, especially in the area oI
the axle attachment
O 11 Check Iuselage structure in the area oI the tail wheel Ior deIormation
and cracks
Control surfaces
O 12 Check control surIaces Ior proper operation
O 13 Check control surIace hinges Ior cracks, security and Iree movement
O 14 Check the balance weights oI the elevator Ior security oI attachment
O 15 Check the spades Ior security oI attachment
Engine
O 1 Check engine mount
Inspector:
Mechanic:
Inspections
Date:
Serial No.:
Hard Landing
UNSCHEDULED MAINTENANCE CHECKS
CHAPTER 05
PAGE 34
05-50-03 Engine Fire
AIter an engine Iire, perIorm a check as described in the
Iollowing:
For damage evaluation consult the manuIacturer, beIore the
aircraIt is put back into service.
O 1 Check all cables and hoses, replace when necessary
O 2 Check engine according to the Lycoming Manual
O 3 Check Iire wall and engine cowling Ior damage by high temperatures
(e.g. signs oI blister on the protective paint) II necessary repaint the
Iire protection paint ("WIEDOFLUGAT" BrandschutzIarbe N 56582
/ T508) .
05-50-04 Lightning Strike
In the event oI a lightning strike in Ilight or on ground check
the Iollowing:
O 1 Check engine according to Lycoming Service Bulletin 401.
O 2 Check the skin oI the strike area Ior burns and melting
O 3 Inspect bolts and Iasteneners Ior burns and melting .
O 4 Check the electrical system, with running engine, Ior correct opera-
tion.
O 5 Check the avionic and antenna Ior correct operation.
O 6 Check the magnetic compass Ior correct readings.
Inspector:
Mechanic:
Inspections
Date:
Serial No.:
Inspector:
Mechanic:
Inspections
Date:
Serial No.:
CHAPTER 05
PAGE 35
05-50-05 Flightline Inspections
These checks include pre-Ilight and postIlight checks, as
they are described in Sections 3 and 4 ("EMERGENCY
PROCEDURES" and "NORMAL PROCEDURES") oI the
PILOTS OPERATING HANDBOOK. When the aircraIt
is in operation, perIorm these checks daily.
CHAPTER 05
PAGE 36
Inspector:
Mechanic:
Date:
Serial No.:
Inspections
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2 as required
General
O
2
O O 1 PerIorm checks given Ior special equipment installed (reIer
to Chapter 95).
O
2
O O 2 Reinstall access panels per Ch. 51.
O
2
O O 3 AircraIt conIorms to SpeciIications oI respective Authority
O
2
O O 4 All required airworthiness directives complied with.
O
2
O O 5 All EXTRA mandatory Service Bulletins complied with.
O
2
O O 6 All vendor Service Bulletins and Service Letters complied
with.
O
2
O O 7 Check Ior proper Ilight manual.
O
2
O O 8 AircraIt papers in proper order.
(Min 6,0mm (1/4")
with newly installed
rudder cables)
Min 3,5mm (1/8")
SaIety Wire Hole
SaIety Stop
Rudder Pedal
Minimum Clearance Check
Figure 5
Coning Check
Figure 6
CHAPTER 05
PAGE 23A

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